Beh, Yong Gui (2025) Milling machining of aluminium alloy using Vegetable oil with waste fly ash additives. Masters thesis, Universiti Teknikal Malaysia Melaka.
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Abstract
This study investigates the incorporation of waste fly ash (FA) as an additive in vegetable oil-based cutting fluids for milling aluminum alloy 6061. Milling aluminum alloys is challenging due to significant heat generation and the need for effective lubrication and cooling. While mineral-based cutting fluids are effective, their environmental impact has driven interest in biodegradable alternatives such as vegetable oils. Waste FA, a byproduct of coal combustion, has potential as a sustainable additive that enhances machining performance. However, the effects of FA additives with different particle sizes and concentrations on milling outcomes remains underexplored. Therefore, this study used the Taguchi method to examine the effects of FA particle sizes (13 μm before ball milling and 1 μm after ball milling) and concentrations (1 wt.% and 2 wt.%) on machining performance. Milling experiments were conducted on aluminum alloy 6061 utilizing a HAAS CNC milling machine, evaluating tool wear, surface roughness, cutting forces, and material removal rate. The findings indicated that the optimal combination for minimizing cutting forces, decreasing tool wear, and enhancing material removal rate was attained with 1 μm FA and a concentration of 2 wt.% (A1B2), yielding the lowest cutting force (47.95 N), minimal tool wear (0.014 mm), and the highest material removal rate (1322.8393 mm³/min). In contrast, 13 μm particles at 1 wt.% concentration (A2B1) yielded the smoothest surface finish, due to their rolling mechanism, but the smaller 1 μm particles were advantageous for their abrasive properties. In conclusion, the integration of waste FA into vegetable oil-based cutting fluids enhances machining performance and offers an eco-friendly substitute to conventional cutting fluids in industrial applications.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Milling-machines, Aluminum alloys, Fly ash |
| Subjects: | T Technology > T Technology (General) T Technology > TJ Mechanical engineering and machinery |
| Divisions: | Library > Tesis > FTKIP |
| Depositing User: | Norhairol Khalid |
| Date Deposited: | 18 Aug 2026 08:05 |
| Last Modified: | 18 Aug 2026 08:05 |
| URI: | http://eprints.utem.edu.my/id/eprint/30347 |
| Statistic Details: | View Download Statistic |
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